I .~.

..

\.f
\.t
Preface
'-'
'-'

'"'-'
Over two decades have passed since the Japan Institute of Plant Mainte-
'-' nance (JIPM)began promoting TPM. Although TPM developed in the fabrica-
'-' tion and assembly industries, it is now actively adopted in process industries.
Japanese companies introducing TPM are currently split approximately fifty-
~ fifty between the two types of industry."
TPM was originally introduced by equipment users but is now being
\.;
implemented increasingly by equipment manufacturers. It is also extending
beyond production departments to encompass R&D, administrative and sup-
'-' port departments, and sales. Interest in TPM is also growing rapidly around the
\.; world. People everywhere are beginning to realize that TPM is one of the keys
to high productivity,excellentquality,low costs,and short lead times.
'-' JlPM's original approach to implementing TPM was described at length in
rPM Development Program (published in English in 1989by Productivity Press).
'-' The program described in that book was slanted toward the fabrication and
assembly industries, however, and had to be adapted to fit process industry
~
I needs. Toreflectthese adaptations and recent TPM developments in both types
of industry, JlPM decided to prepare two new editions specifically tailored to
each industry.
The implementation program described in the process-industry edition
was compiled with process-industry characteristics in mind. The book identi-
fies eight major losses common to all process industries in Chapter 2 and
describes the thinking behind identifying and eliminating process and equip-
ment failures. It also explains the application of P-M analysis in focused
improvement projects,using actual process-industry examples in Chapter 3.

It Editor's note: In the United States, slightly over one-third of surveyed companies implementing TPM in
1990were in process industries. Anecdotal evidence today suggests that this percentage is increasing.

xiii
xiv TPM IN PROCESS INDUSTRIES

Extensive TPM experience has amply demonstrated the effectiveness of

the step-by-step approach. Chapter 4 details a step-by-step autonomous main-
tenance implementation process specially designed for application to process
industries. Chapter 5 describes how a step-by-step approach can be used effec-
tively for developing a planned maintenance system. ~,
I
In this book's review of early equipment management (Chapter 6), maxi-
mum emphasis is placed on upstream stages with the aim of shortening com-
missioning periods and achieving instant, problem-free startup. Additional
chapters also describe step-by-step programs for developing a quality mainte-
nance system (a method of building quality into the product through the equip- """
I
I

ment) (Chapter 7), and for educating and training the high-caliber operators
and maintenance technicians now needed in process industries (Chapter 8).
Interest in TPM in administrative and support departments is increasing
rapidly in Japan, and Chapter 9 is devoted to this new area. Safety program-
ming is also addressed for the first time in this process industry edition (Chap-
ter 10), because eliminating accidents and pollution is an integral part of the ~
I
eight TPM core activities described in this book. Chapter 11explains the differ-
ences between TPM small-group activities and QC circle activities and suggests
methods for energizing small groups as the driving force behind TPM.
The final chapter discusses the philosophy of goal-setting, details the types
of performance indicators used in companies today, and gives examples of
actual TPM benefits achieved.
Process industries are just beginning to apply TPM, and many companies
are expected to introduce it in the future. On behalf of all the authors, I hope
that this book may in some way help those companies introduce TPM smoothly
and experience its undoubted benefits.

Tokutaro Suzuki
ViceChairman, Japan Institute of Plant Maintenance
Director,TPM General Research Institute

•
\.t
..
~

'-'
\I
~

'--'
~
Contributors
'-'
~

\,

'-'
"
~
Supervising Editor:
TokutarOSuzuki
ViceChairman, Japan Institute of Plant Maintenance OIPM)

'"'-' Director, TPM General Research Institute

Authors:
Tokutaro Suzuki (as above)-Chapter 1
'-'
'"'" Ainosuke Miyoshi-Chapters 2 and 12
Principal Consultant, Japan Institute of Plant Maintenance
Director, TPM General Research Institute, Technical Center

""
\.;
KOichiNakazato-Chapters 3 and 4
TPM Consultant, Japan Institute of Plant Maintenance
'" Manager, TPM General Research Institute,

'"'-' Technical Center, Technical Division

Hisao Mizugaki - Chapter 5

'"'-' TPM Consultant, Japan Institute of Plant Maintenance

TPM General Research Institute,
..., Technical Center, Technical Division

\.t xv

"
xvi TPM IN PROCESS INDUS'I'RIES
.,"'"
~

.,
Makoto Saitoh-Chapter 5 "'"
.~
TPM Consultant, Japan Institute of Plant Maintenance
TPM General Research Institute, ~
TechnicalCenter, Technical Division

Hisamitsu Ishii-Chapters 6 and 8

TPM Consultant, Japan Institute of Plant Maintenance
'""
~
TPM General Research Institute,
TechnicalCenter, TechnicalDivision
""
I

Ikuo Setoyama-Chapters 7 and 10

TPM Consultant, Japan Institute of Plant Maintenance
""
TPM General Research Institute,
TechnicalCenter, TechnicalDivision
""
Makoto Harada-Chapter 9
""
~
TPM Consultant, Japan Institute of Plant Maintenance
TPM General Research Institute, ~
TechnicalCenter, TechnicalDivision

Akira Ichikawa-Chapter 11
"'"
.~

TPM Consultant, Japan Institute of Plant Maintenance

TPM General Research Institute,
TechnicalCenter, TechnicalDivision "'"
"'"
"'"
"'"
"'"
"'"
~

"'"
"""
"'"
.. "'"
"'"
~
 ..

1
Overview of rPM
in Process Industries

Japan's process industries introduced preventive maintenance (PM) rela-

tively early because production output and rate, quality, safety,and the envi-
ronment depend almost entirely on the state of plant and equipment. The
preventive and productive maintenance systems*introduced by Japanese pro-
cess industries played a major role in improving product quality and produc-
tivity. They contributed significantly to overall progress in maintenance
management and expertise in such areas as setting up specialized maintenance
organizations, creating equipment management systems, improving equip-
ment technology,and raising maintenance productivity.

ORIGIN AND DEVELOPMENT OF TPM

While the process industries focused on preventive and productive main-

tenance, the fabrication and assembly industries invested heavily in new
equipment in an effort to become less labor intensive. The equipment used by
these industries has become increasingly automated and sophisticated, and
Japan is now the world leader in the use of industrial robots. This trend toward
automation, combined with the trend toward just-in-timeproduction, stimulat-
ed interest in improving maintenance management in the fabrication and

It Preventive maintenance was introduced to Japan from America in the 195Os, when Japanese process
industries were beginning to get back on their feet after the war. Productive maintenance, developed in the
19605, incorporates such disciplines as maintenance prevention design, reliability and maintainability
engineering, and economic engineering to enhance the economic efficiency of equipment investment for
the entire life of equipment.

1
2 TPM IN PROCESS INDUSTRIES

assembly industries. This gave birth to a uniquely Japanese approach called

total productive maintenance (rPM), a form of productive maintenance involv-
ing all employees.

The Spread of TPM

TPM first took root in the automobile industry and rapidly became part of
the corporate culture in companies such as Toyota, Nissan, and Mazda, and
their suppliers and affiliates. It has also been introduced by other industries,
such as consumer appliances, microelectronics, machine tools, plastics, film,
and many others.
Having introduced preventive maintenance, the process industries then
began to implement TPM. An increasing number of process plants have intro-
duced TPM over the past few years in industries such as food, rubber, oil
refining, chemicals, pharmaceuticals, gas, cement, papermaking, iron and
steel, and printing.
Initially, corporate TPM activities were limited to departments directly
involved with equipment, such as production. As Figure 1-1 shows, however,
administrative and support departments, while actively supporting TPM in
production, are now applying TPM to enhance the effectiveness of their own
activities. TPM improvement methods and activities are also being adopted in
product development and sales departments.
This last trend underlines the increasing tendency to consider production
processes and equipment at the product development stage in an effort to sim-
plify production, improve quality assurance, and enhance and reduce the
startup period for new production. These issues are of particular concern in
process industries today as product diversification continues and product life
cycles shorten.
Interest in TPM outside Japan has also expanded in recent years. Many
companies in the United States, Europe, Asia, and South America are planning
to or are actively pursuing TPM.*

Why Is TPM So Popular?

There are three main reasons why TPM has spread so rapidly throughout
Japanese industry and why companies outside Japan are becoming interested:
It guarantees dramatic results, visibly transforms the workplace, and raises the
level of knowledge and skill in production and maintenance workers .

.. See the Appendix for a review of TPM implementation activities in the United States and other parts of
the world.
'-'
..
i\.l
I
:~ Overview of TPM in Process Industries 3

~
i
!\.,
I
\.,

\.;
Top Management
~

'-'
'-'
~

'-' TPM Stage 2

~
TPM Stage 1: Production-department TPM
TPM Stage 2: Companywide TPM embracing production, development, sales, and administration
'--' J

Figure 1-1. From Production-Department TPM to Companywide TPM

"'-' Significant Tangible Results

\.; Companies practicing TPM invariably achieve startling results, particularly

in reducing equipment breakdowns, minimizing idling and minor stops (indis-
'-' pensable in unmanned plants), lessening quality defects and claims, boosting
productivity, trimming labor and costs, shrinking inventory, cutting accidents,
'-' and promoting employee involvement (as shown by increased submission of
improvement suggestions). (SeeTable1-1.)
~

\.; Transforming the Plant Environment

\.I Through TPM,a filthy,rusty plant covered in oil and grease, leaking fluids,
and spilt powders can be reborn as a pleasant, safe working environment. Cus-
\.I tomers and other visitors are impressed by these changes, and their confidence
in the plant's products increases.

'-' " Transforming the Plant Workers

'-' As TPM activities begin to yield concrete results (improving the.working

~
environment, minimizing breakdowns, improving quality, reducing change-
over times, and so on), workers become motivated, involvement increases, and
improvement suggestions proliferate. People begin to think of TPM as part of
'-' their job.
'-'
~
4 TPM IN PROCESS INDUSTRIES

Table 1-1. Examples of TPM Results

Tangible Benefltp
p •... Net productivity up by 1.5 - 2x
1 1 .
o Number of sudden breakdowns down to 10 - 250 of baseline
o Overall plant effectiveness 1.5 - 2X
Q .... Process defect rate down 90%
Customer claims down 75%
C . . . . Production costs down 30%
D . . . . Product and work-in-process inventories halved
S . . . . Shutdown accidents 0
P.?lIutionincidents 0
M .... Improvement suggestions up by 5 -10X

Intangible BenefIts
o Achieving full self-management - operators have ownership of the equipment,
they look after it by themselves without direction.
o Eliminating breakdowns and defects and instilling confidence and a can-do attHude.
o Making previously dirty, grimy, and oily workplaces unrecognizably clean, bright and lively.
o Giving plant visitors a better image of the company and thereby winning more orders.

TPM helps operators understand their equipment and widens the range of
maintenance and other tasks they can handle. It enables them to make new dis-
coveries, acquire fresh knowledge, and enjoy new experiences. It strengthens
motivation, engenders interest in and concern for equipment, and fosters the
desire to maintain equipment in peak condition.

SPECIAL ~EATURES OF PROCESS INDUSTRIES

Certain unique features and concerns distinguish process industries from

the fabrication and assembly industries where TPMwas born.
Diverse production systems. The term "process industry" covers a wide
variety of industries including oil refining, petrochemicals, general chemicals,
iron and steel, power generation, gas, papermaking, cement, food, pharmaceu-
ticals, and textiles. Process plants in these industries employ a mixture of dif-
ferent production regimes, ranging from completely continuous integrated

..
 ..

Overview of TPM in Process Industries 5

production to pure batch production. Also, the trend toward increased product
diversification and high-variety,small-lot production has led in many cases to
both process and fabrication/assembly production in the same plant.
Diverse equipment. Inprocess industries, production processes consist of a
combination of unit operations such as pulverization, dissolution, reaction, fil-
tration, adsorption, concentration, crystallization, separation, molding, drying,
cooling, and screening, together with the handling and transportation of vari-
ous substances. Equipment includes static units such as columns, tanks, heat
exchangers, kettles, and furnaces; rotating machinery such as pumps, compres-
sors, motors, and turbines; and the piping, electrical,and instrumentation sys-
tems that connect them.
Use of static equipment. Staticequipment is a particularly noteworthy fea-
ture of process industries. The special nature of such equipment requires TPM
activitiesthat focus on the relationship between process conditions and product
quality and include techniques for diagnosing corrosion, cracking, burning,
blocks,leaks, and so on.
Centralized control and few operators. Unlike in fabrication and assembly
industries, control in process industries is centralized. Many process industries
employ continuous, integrated production with centralized control of large
equipment complexes. A wide range of equipment is often controlled by a
handful of operators.
Diverse equipment-related problems. In addition to blocks, leaks, and
other process problems, process industry equipment is often plagued by faults
such as cracking, rupture, corrosion, seizure, fatigue, slack, parts falling off,
wear, distortion, burning, short-circuiting, faulty insulation, wire breaks,
misoperation, current leaks, and overheating. The most common problems,
however, are corrosion,leaks, and blocks.
High energy consumption. Many processes in process industries, such as
dissolution, reaction, crystallization, baking, and drying, are energy intensive
and consume-largeamounts of electrical power, fuel, water, and so on.
Standby units and bypasses commonly used. To alleviate the effects of
breakdowns, it is standard practice to install standby equipment, bypasses, and
soon.
High accident and pollution risk. Some processes handle hazardous or
poisonous substances and are operated at high temperatures and pressures,
6 TPM IN PROCESS INDUSTRIES

risking explosion and pollution of the plant and its surroundings. This makes
strict plant management essential, as well as careful adherence to various statu-
tory regulations.
Poor working environment. Intermediate and final products handled in
process industries usually consist of bulk powders, liquids, or solids. While it is
considered inevitable that the working environment will become dirty as a
result of these being scattered, overflowing, leaking, and so on, such conditions
frequently cause equipment problems.
Shutdown maintenance. Shutdown maintenance is a major feature of pro-
cess industries. Carefully planned, systematically implemented shutdown
maintenance is considered the most effective way of preventing breakdowns.
However, since shutdown maintenance is time-consuming and labor-intensive,
it is also expensive, Finding the most effective way of performing shutdown
maintenance in view of its cost and the losses it incurs is therefore a perennial
concern in process industries.

DEFINITION OF TPM

Because early TPM activities were targeted at production departments,

TPM was originally defined by the Japan Institute of Plant Maintenance (JIPM)
to include the following five strategies:
1. Maximize overall equipment effectiveness.
2. Establish a comprehensive PM system covering the life of the equip-
ment.
3. Involve all departments that plan, use, and maintain equipment.
4. Involve all employees from top management to front-line workers.
5. Promote PM through motivation management, i.e. autonomous small-
group activities.
Now, however, TPM is applied throughout many organizations - in many
pre-production and product development departments as well as administra-
tive and sales departments. To reflect this trend, JIPM introduced a new defini-
tion ofTPMin 1989, with the following strategic components:
1. Build a corporate constitution that will maximize the effectiveness of
production systems.
2. Using a shop-floor approach, build an organization that prevents every
type of loss (by ensuring zero accidents, zero defects, and zero failures)
for the life of the production system.
 Overview of TPM in Process Industries 7

l"
\.., 3. Involve all departments in implementing TPM, including development,
sales, and administration.
'-' 4. Involve everyone - from top management to shop-floor workers.
5. Conduct zero-lossactivity through overlapping small-group activities.
'-'
\., EQUIPMENT MANAGEMENT IN PROCESS INDUSTRIES

\., Equipment management in process industries has three aspects as Figure

1-2shows. The first involves planning for the entire life cycle of equipment. The
'-' technology-cost tradeoff must be pursued throughout the engineering and
maintenance phases - from the time a piece of equipment is first planned until
'-' it is finally replaced. The second aspect concerns the type of maintenance to be
performed, that is, the approach (preventive, corrective, predictive, and so on)
\.;
and its frequency (whether scheduled or unscheduled). To eliminate failures,
companies must skillfully combine these different maintenance approaches.
'-'
'-' Maintenance Approach

'-' Division of
Responsibility
'-'
~ Planning

'-' Equipment
Design
~\'"
#
~~e
.~e
Life Cycle Construction

Operation

'-' Maintenance

\,
V
'\.,.- Object of Control
Coh.rnns and tanks

'-' Heat exchangers

Electrical systems
Instrumentation
'\..I Piping
Fumaces
\.; Rotating machinery

'\.,
Figure 1-2. The Concept of Equipment Management
\.,

'-'
~
8 TPM IN PROCESS INDUSTRIES

The third aspect involves allocating responsibility for maintenance, that is,
deciding whether tasks will performed autonomously by production opera-
tions or by maintenance specialists. At presen~,maintenance and production
departments tackle some maintenance tasks independently and some in collab-
oration. The boundary is likely to shift, however, as equipment becomes
increasingly automated and requires less human intervention. The types of
equipment being managed must also be considered. The combination of strate-
gies adopted to achieve zero breakdowns, zero defects, and zero accidents will
vary depending on the particular category of equipment, such as columns, I
tanks, heat exchangers, piping, rotating machinery, electrical systems, instru-
mentation, and furnaces.

TPM DEVELOPMENT

TPM is normally implemented in four phases (preparation, introduction,

implementation, and consolidation), which can be broken down into twelve
steps. (SeeTable1-2.)

Preparation Phase (Steps 1-5)

It is vital to lay the foundation for a TPMprogram carefullyand thoroughly.

If planning is slipshod, repeated modifications and corrections will be needed
during implementation. The preparation phase starts with top management's
announcement of its decision to introduce TPM and is complete when the TPM
development master plan has been formulated.

Step 1: Top Management Announces Its Decision to Introduce TPM

All employees must understand why their company is introducing TPM

and be fully.aware of its necessity.Rising raw and intermediate material costs,
falling product prices, and other upheavals in the business environment are
forcingindustry to organize itself more effectively.Many companies are adopt-
ing TPM as a way of solving their complex internal problems and riding out
the economic storm. Needless to say, top management must consider these
points carefullybefore announcing its decision to introduce TPM.
When top management does make this commitment, however, it should
declare the intention to see the TPM program through to the end. This informs
all employees and interested outside parties that management understands the

..
1-

Overview of TPM in Process Industries 9

long-term value of TPM and will provide the physical and organizational sup-
port needed to solve the various problems that are likely to surface during
implementation. Preparation for rPM begins formally when this announce-
ment is made.

Table 1-2. The Twelve New TPM Development Program Steps

Step Key Point

Preparation
1. Fonnally announce decision to introduce TPM Top management announcement at in-house meeting;
publish in company magazine
2. Conduct TPM introductory education • Senior management: group training for
and publicity campaign specific management levels
• General employees: slide shows
3. Create a TPM promotion organization • Steering committee and specialist subcommittees
• TPM Promotion Office
4. Establish basic TPM policy and goals • Set baselines and targets
• Forecast effects
5. Draft a master plan for implementing TPM From preparation stage to application for PM Prize

Introduction
6. Kick off TPM initiative Invite customers, affiliates, and subcontractors
Implementation
7. Build a corporate constitution designed Pursue the ultimate in production effectiveness
to maximize production effectiveness
7-1 Conduct focused improvement activities Project-team activities and workplace
small-group activities
7-2 Establish and deploy autonomous Proceed step-by-step, with audits and
maintenance program pass certificates at each step
7-3 Implement planned maintenance program • Corrective maintenance
• Shutdown maintenance
• Predictive maintenance
7-4 Conduct operation and maintenance Group education for group leaders who
skills training then pass on their training to members
8. Build an ear1ymanagement system Develop products that are easy to use
for new products and eqUipment and equipment that is easy to use
9. Build a quality maintenance system Establish, maintain, and control
conditions for zero defects
10. Build an effective administration and support system • Increase production-support effectiveness
• Improve and streamline administrative
functions and office environments
11. Develop a system for managing health, Assure an aCCident-free,pollution-free environment
safety, and the environment
Consolidation
12. Sustain full TPM implementation and raise levels • Apply for PM Prize
• Aim for even higher targets
 10 TPM IN PROCESS INDUSTRIES

Step 2: rPM Introductory Education

Before a TPM program can be implemented it must be understood. To

achieve this, some people attend outside seminars, and an in-house training
program is planned and implemented.

Step 3: Create a rPM Promotion Organization

TPM is promoted through a structure of overlapping small groups. As Fig-

ure 1-3 shows, in this system leaders of small groups at each organizational
level are members of small groups at the next higher level. Top management
itself also constitutes a small group. This system is extremely effective for
deploying top management policy and goals throughout an organization.

President

Plant
superintendents

Subsection
managers

Group leaders

Ordinary
employees

Figure 1-3. Overlapping Small-Group Activities

Establish a TPM promotion officeresponsible for developing and promot-

ing effectiveTPM promotion strategies. Tobe effective,the officeshould be run
by a permanent, full-time staff, assisted by various committees and subcommit-
tees. Its functions include preparing the TPM master plan and coordinating its
promotion, devising ways to keep the various TPM activities on track, spear-
heading focused campaigns, disseminating information, and arranging pub-
licity. The promotion officeplays an especially important role in managing the
implementation of autonomous maintenance and focused improvement activi-
ties (see Chapters 3 and 4).

..
 ..
Overview of TPM in Process Industries 11

Step 4: Establish Basic rPM Policy and Goals

A company's basic TPM policy must be an integral part of its overall busi-
ness policy and should indicate the goals and directions of the activities to be
carried out. (See Figure 1-4.)TPM goals should relate to the company' s long-
and mid-range business goals and should only be decided after thorough con-
sultation among everyone involved, including top management. The TPM pro-
gram lasts for the length of time required to attain these goals.

• With everyone's participation, to aim for zero breakdowns and zero defects and seek to maximize overall
equipment effectiveness
• To create well-engineered equipment and use itto build in quality
• To develop equipment-competent personnel and have them exercise their full potential
• To create lively, energetic workplaces

Annual Policy and Companywlde TPM Goals

FY 1986 Policy I September 1988 Target

FY 1987 Policy I (relative to April 1986 baseline)
FY 1988 Policy Number of failures: 111ooer less

•
1. Establish a Number of minor stops: 1/20 or less
profitable (Mean time between minor stops): (4 h or more)
corporate
constitution Processing productivity: at least 50% higher
2. Promote a ·Cut Materials wastage rate: 1/3 or less
- Total Cost by Half" Total cost 60% or less
'-- campaign Number of shutdown accidents: o
3. Promote TPM

Figure 1-4. Example of Basic TPM Policy and Goals (Kansal NEe)

Express goals numerically as far as possible. Toset goals, start by establish-

ing clear baselines. These should provide a snapshot of the existing situation
and be expressed partly quantitatively and partly qualitatively. Setting a goal
means aiming for a desirable level of attainment above a particular baseline.
Deciding how far above the baseline to set the goal is always the most difficult
question. Goals should be very challenging, but also achievable. See Chapter 12
for more on establishing goals and progress indicators.
12 TPM IN PROCESS INDUSTRIES

Step 5: Draft a rPM Master Plan

To formulate a master plan for implementation, first decide what activities

must be pursued to achieve the TPM goals. This is an important step, because it
makes people think about the most efficient ways of bridging the gaps between
baselines and goals.
The eight core TPM activities are:
• Focused improvement
• Autonomous maintenance
• Planned maintenance
• Education and training
• Early management
• Quality maintenance
• Administrative and support department activities
• Safety and environmental management
Other important activities include:
• Diagnostics and predictive maintenance
• Equipment management
• Product development and equipment design and construction
These activities need budgets and must be properly supervised. A sched-
ule should be drawn up for each activity and integrated in the master plan.

Introduction Phase - Step 6: Kick Off TPM Initiatives

Once the master plan has been approved, the TPM kick-off can take place.
The kick-off should be designed to cultivate an atmosphere that raises morale
and inspires dedication. In Japan, it is often a companywide meeting to which
client companies, affiliates and subcontractors are invited. At the meeting, top
management reconfirm their commitment to implementing TPM and report on
the plans developed and the work accomplished during the preparation phase.

Implementation Phase (Steps 7-11)

During the implementation phase, selected activities designed to achieve

the targets shown in the master plan are carried out. The order and timing of
the activities in Steps 7-11 should be tailored to suit the particular characteris-
tics of the company, division, or plant. Some activities may be carried out con-
currently. The fundamental TPM activities are summarized below .

..
 ..
Overview of TPM in Process Industries 13

Consolidation Phase - Step 12: Sustain Levels and Refine

In Japan, the first stage of a TPM program ends when a company wins a
PM Prize. However, the company's TPM activities must not stop there. Embed
them firmly in the corporate culture and continue to make them more effective.
A company grows by continually pursuing higher and higher goals -
goals that reflect a vision of what the company believes it ought to become.
Businesses are struggling to map out their development plans for the fast-
approaching twenty-first century.Their TPMprograms must be able to support
them in this.
'-' Recently, more companies are realizing the importance of locking into
\., place the improvements their initial TPM program brings. Such companies are
introducing a further stage to their activities with the aim of winning the Spe-
i\.i
I
cial PM Prize.
i
i
.\.t
FUNDAMENTAL TPM DEVELOPMENT ACTIVITIES
'-' Companies must select and implement activities that will achieve the
\.t goals of TPM effectively and efficiently. Although different companies may
choose slightly different activities, the eight described below are the most
'-'
i
common. They have been shown to yield excellent results when properly pur-
sued, and they are the foundation and support of any successful TPM devel-
:'-' opment program.

'-' Step 7·1: Focused Improvement

~
Focused improvement is an improvement activity performed by cross-func-
\.I tional project teams composed of people such as production engineers, mainte-
nance personnel, and operators. These activities are designed to minimize

""
\..I
targeted losses that have been carefullymeasured and evaluated.
In addition to the seven major losses experienced in fabrication and assem-
bly industries, process industries sustain three additional types of loss: people-
related losses such as work and misoperation losses; raw-materials losses such
'-' as yield, unit-consumption, and recycling losses; and management losses such
.-..., as shutdown maintenance and energy losses. (Chapter 2, Maximizing Produc-
tion Effectiveness, provides a detailed review of the approach to identifying,
~ measuring, and attacking the various individual losses that occur in process
industries.)
'-' In process industries, focused improvement activity is directed at a specific
\, object such as a process, a flow system, an item of equipment, or an operating

"
~
14 TPM IN PROCESS INDUSTRIES

procedure. For example, process design must be an integral part of product

development and improvement. A focused improvement project can address
vital, related issues such as establishing criteria for selectingprocesses.and their
conditions, discovering deficienciesin process conditions, and finding and clos-
ing gaps between actual and ideal process conditions.
The trend toward unattended operation is well advanced in process indus-
tries and will probably be taken even further in the future. For this reason,
ideas for stabilizing processes and eliminating equipment breakdowns, idling,
and minor stops are also important topics for focused improvement.
When the focus is strictly on equipment, project teams follow a similar
approach to that developed in fabrication and assembly industries. They docu-
ment and analyze the major equipment-related losses, then study the equip-
ment carefully to identify the process conditions it is required to provide and to
ensure that it can fulfill them.
Whether the focus is on the process, work flow, equipment, or operating
procedures, however, focused improvement activity is founded on effectiveuse
of cause analysis methods, such as why-why analysis and P-M analysis.
Chapter 3, Focused Improvement, provides a detailed review of the planning
and management of focused improvement team activities, the methods used,
strategies for specificlosses,and case examples.

Step 7-2: Autonomous Maintenance

Autonomous maintenance, detailed at length in Chapter 4, is one of the

most distinctive activities in TPM. After preventive maintenance was intro-
duced into Japan from America, operation and maintenance were formally sep-
arated. As operators lost ownership of their equipment, they gradually lost
their sense of responsibility for maintaining it.
The autonomous maintenance practiced in rPM reverses this tendency.
Operators become involved in routine maintenance and improvement activities
that halt accelerated deterioration, control contamination, and help prevent
equipment problems. Becauseprocess plants employ a small number of opera-
tors in relation to the number and size of equipment units, strategies for achiev-
ing autonomous maintenance goals must be adapted somewhat from the
traditional approach followed in fabrication and assembly industries. When tai-
loring autonomous maintenance to individual process environments, planning
teams must:
• Consider how autonomous maintenance steps can be conducted most
effectivelyon different types of equipment

..
 ..
Overview of TPM in Process Industries 15

• Investigate the relative importance of different equipment items and

determine appropriate maintenance approaches
~ • Prioritize maintenance tasks
• Allocate responsibilities appropriately between production and special-
'-' ized maintenance personnel
\., Autonomous maintenance activities are typically implemented in steps
and are only effective if the progression from one step to the next is strictly
I~ controlled. To manage this, appoint official auditing groups and lay down
I pass/fail standards. A plant's top management should give final approval for
'-' groups to graduate from one step and move on to the next.
Why is close control so important? Initial cleaning (Step 1), for example,
.,-,
, involves much more than merely cleaning and tidying the equipment and adja-
cent areas. If team efforts are not focused on identifying and treating problems
found in the course of thorough cleaning, the goals of eliminating and control-
ling deterioration cannot be achieved.
Similarly,depending on the plant's location, salt spray, rain, snow, and so
on, may corrode the equipment and erode its foundations. Products such as
powders, liquids, solids, gases, and so on can also cause accelerated deteriora-
tion of equipment, through scattering, leaking, blocks, and so forth. How such
deterioration is treated will depend in part on the environment, the equipment,
or form of the product. However, if Step 2 of an autonomous maintenance pro-
-
gram (action against contamination sources and inaccessible places) is not
'-' properly implemented, the program will slip right back to Step' 1 or even fur-
ther. Step-by-step auditing of team activities to keep them properly focused is
"- essential for successful implementation of autonomous maintenance. For a
~
detailed discussion of autonomous maintenance activities adapted for process
industry environments, see Chapter 4, Autonomous Maintenance.
~

\..; Step 7-3: Planned Maintenance

\.of Planned or scheduled maintenance, detailed in Chapter 5, embraces three

forms of maintenance: breakdown, preventive, and predictive. Like other TPM
~ activities, building a planned-maintenance system should done systematically,
one step at a time.
~ The purpose of performing predictive and preventive maintenance is to
eliminate breakdowns, but even when systematic maintenance practices are
~
carried out, unexpected failures still occur. Such failures reveal inadequacies in
~
the timing and content of maintenance plans and highlight ineffective recur-
rence-prevention measures. In TPM,planned maintenance activities emphasize
'-'
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16 TPM IN PROCESS INDUSTRIES

monitoring mean times between failures (MTBF)and using that analysis to

specify the intervals for tasks in annual, monthly, and weekly maintenance
calendars.
A classic example of planned maintenance activity is shutdown mainte-
nance.* To make them more effective,companies are preparing for shutdowns
earlier and earlier. Their goal is to layout reliable plans before the job begins.
Becausethe tasks performed during shutdown maintenancefollowa set pattern,
it is helpful to base the work plan on a work breakdown structure (WBS)dia-
gram. This diagram facilitatesaccurate estimation of the tasks to be performed.
during shutdown maintenance, along with their sizes. It can be used to gauge
the staff and materials needed for the job and to monitor the budget and the
achievement of the objectives. (See pp. 186-188 for more about the WBS
diagram.)

Step 7-4: Training

A company's workforce is a priceless asset.and all companies must train

their employees systematically.Process-industry workers are becoming scarcer,
increasinglyelite, and more multiskilled, so training must be an integral part of
a career development system. Visualize the type of people you want your
training programs to produce. In other words, identify the specificknowledge,
skills, and management abilities you want them to have and then design train-
ing that will achieve your vision. (SeeChapter 8 for models of successful pro-
gram design.)
Training must also be tailored to serve the individual's needs. Assess each
person to measure his or her grasp of the required knowledge and skills and
pinpoint weaknesses, then use the results to make the general training more
effective. Workers and their supervisors should discuss the results of this
assessment annually and use them to set the next year's targets and plan the
next phase.
Also set firm schedules for achieving program targets. Decide the kind of
people you want to have in how many years' time, then draw up comprehen-
sive plans for on-the-job and off-the-job training (including seminars and
courses) designed to achieve this.

..Thanks to a change in the law, shutdown maintenance of large plants in Japan can now be performed
once every two years instead of annually, depending on the type and state of the equipment, and pro-
vided that an examination has been passed and official authorization received. Implementing a TPM
program is of great assistance in obtaining this authorization.

..
 Overview of TPM in Process Industries 17

Step 8: Early Management

Early management, addressed in Chapter 6, includes both early product

management and early equipment management. The purpose of these activities
is to achieve - quickly and economically - products that are ea$y to make
and equipment that is easy to use. This section highlights early equipment
management.
Early equipment management concerns equipment users, engineering
companies, and equipment manufacturers, and addresses the following areas:
• Equipment investment planning
• Process design
• Equipment design, fabrication, and construction
• Testoperation
• Startup management.
All activities from the initial design of a piece of equipment to its installa-
tion and test operation can be viewed as a single, giant project. The project
starts with process design, basic plant design, and detailed design and unfolds
to include procurement, fabrication, construction, and test operation. In plan-
ning such a project, the project team determines the plant and equipment's
required technical levels (functions and performance) together with its avail-
ability levels (reliability,maintainability, etc.), and then establishes budgets and
schedules to achieve them.
In designing a plant, various designs are performed: functional design,
reliability and maintainability design, safety design, and economy design.
Establishing maintenance prevention (MP) specifications and performing MP
design, in particular, help ensure that the plant and equipment are reliable and
easily maintained. Several design reviews should be performed in the course of
designing, fabricating, and constructing a plant.
After completing these activities, teams install the equipment, perform test
operation, and initiate the startup management phase. Startup management is
an activity designed to achieve as quickly as possible the conditions for its own
termination, that is, conditions that enable the plant to start producing stable-
quality product with zero failures. In TPM this efficient approach to stable, full-
scale production is known as "vertical startup."
For an overview of TPM early management activities for equipment and
product design, as well as startup management, see Chapter 6.
18 TPM IN PROCESS INDUSTRIES

Step 9: Quality Maintenance

Quality maintenance (QM) is a method for building in quality and prevent-

ing quality defects through the process and tlirough the equipment. In quality
maintenance, variability in a product quality characteristic is controlled by con-
trolling the condition of equipment components that affectit.
Quality characteristics are mainly influenced by the four production
inputs: equipment, materials, people's actions (skills),and methods used. The
first step in quality maintenance is to clarify the relationships between these
factors and a product's quality characteristics by analyzing quality defects. In
process industries, the effectof equipment on quality characteristicsis particu-
larly important.
In processjndustries, the process determines the type of equipment needed.
Therefore, teams should focus first on the process, then on the equipment. In
other words, first clarify the relationships between product quality and process
conditions and ascertain the precise process conditions required for producing
perfect product.
Equipment is a means of implementing a process. Therefore, applying a
QM approach in equipment design, teams begin by identifying the components
that will affect the product's quality characteristics. These are called "quality
components." Next, they pinpoint the quality component conditions required
to maintain the quality characteristics.
Quality maintenance used in this way assures quality at the very begin-
ning of the production process. (SeeChapter 7 for a detailed review of the qual-
ity maintenance methodology and examples of its application.)

Step 10: rPM in Administrative and Support Departments

Administrative and support departments play an important role in back-

ing up production activities.The quality and timeliness of the information sup-
plied by administrative and support departments has a major impact on these
activities.
TPM activities performed by administrative and support departments
must not only support TPM in the workplace; they should also strengthen the
functions of the departments themselves by improving their own organization
and culture. Compared with production, however, it is not as easy for adminis-
trative and support departments to measure the effects of their activities. A
TPMprogram in such a department must aim to create an "information factory"
and apply process analysis to streamline the information flow.Think of admin-
istrative and support departments as process plants whose principal tasks are
\,..
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~
Overview of TPM inProcess Industries 19
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~ to collect, process, and distribute information. This understanding makes it
easier to promote and measure autonomous maintenance, focused improve-
'-' ment, and other TPM activities in an officeenvironment.
Autonomous maintenance in administrative departments aims for effi-
I\"- cient, trouble-free work execution from two angles: administrative function and
I
administrative environment. Implemented step by step, the first set of activities
'-' reduce costs and boost efficiencyby improving administrative processes. The
second set of activities removes obstacles to effectivework hidden in the physi-
'-' cal and psychologicalenvironment.
\... Focused improvement of administrative tasks aims to improve their effi-
ciency and speed and reduce the number of staff required. To achieve this,
automate office tasks and install electronic data-processing systems such as
'- local-area networks. At the same time, increase administrative efficiency to
\., support the planning and decision-making of executives and managers. See
Chapter 9 for a more detailed review of TPM activities in officeenvironments.
'-'
Step 11: Safety and Environmental Management
'-
\. Assuring safety and preventing adverse environmental impacts are impor-
tant issues in process industries. Operability studies combined with accident
\.,. prevention training and near-miss analysis are effective ways of addressing
these concerns. Safety is promoted systematically as part of TPM activities. As
'-' with all TPM activities, safety activities are implemented step by step.
\., Certain issues are of particular importance in the process environment. For
example, it is particularly important to incorporate fail-safemechanisms - that
\.,. is, to design equipment that will remain safe even when people do not take the
I
proper precautions. Assuring safety during shutdown maintenance is also
'--' important. In process industries, shutdown maintenance requires considerable
assistance from outside subcontractors, as do operations such as cleaning. This
'- makes it doubly important to ensure safety during such operations. Check the
skills and qualifications of subcontract workers well in advance whenever pos-
\.t sible. Take every practicable step , to assure safety, including giving rigorous
safety training and carefully supervising the work itself. See Chapter 10 for
\.
examples of safety training programs and activities.

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~
Step 12: Sustaining rPM Implementation and Raising Levels

There are several keys to maintaining TPM levels once they are achieved.
~
Building strong teams at every level and staffing a promotion organization
\J

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1
20 TPM IN PROCESS INDUSTRIES

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helps integrate TPM in daily work, for example. Following the systematic, step-
by-step approach recommended for rPM activities helps lock in results.
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~

Emphasizing a continuous-improvement approach through the CAPD cycle, ~

continually revising goals upward, and settihg new challenges, like the PM
Special Prize, are also helpful. None of these approaches will be effectivewith- ~
out the support of careful, continuous, and concrete measurement. Start with
clear baselines arid document improvement results regularly and in detail. Use
management indicators that show everyone (at every level) what concrete
progress is being made and motivate their continued involvement. See Chapter
'"'
12, Measuring rPM Effectiveness, for a detailed summary of key management
indicators to use for charting and encouraging progress in TPM activities.
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